BE1018191A5 - METHOD FOR MANUFACTURING A LAMINATE PRODUCT, LAMINATE PRODUCTS OBTAINED THEREOF AND APPARATUS FOR ACHIEVING THE METHOD. - Google Patents

Abstract

Method for manufacturing a laminate product comprising at least one laminate layer (1), wherein, to form the laminate layer (1), on the one hand, at least one decor sheet (2) is formed by a decor (5) in a decor application process (6) to be arranged in the form of a motif on a decor support (4) and, on the other hand, subsequently to provide the decor sheet (2) with a resin application process (7) with resin (3), characterized in that said decor application process (6) and said resin application process (7) can be carried out in-line with each other.

Description

Method for manufacturing a laminate product, laminate products obtained thereby and device for realizing the method.

This invention relates to a method for manufacturing a laminate product, as well as to laminate products obtained according to this method and to a device for realizing the method.

In particular, the invention relates to a method for manufacturing a laminate product, comprising at least one laminate layer, wherein, to form the laminate layer, on the one hand, at least one decor sheet is formed by a decor in the form of a motif in a decor application process to be applied to a decor support and, on the other hand, subsequently the decorative sheet is provided with resin by means of a resin application process.

According to the invention, a laminate product is to be understood to mean any product which consists at least of a laminate layer, which in itself comprises at least one decorative sheet, which is formed from a decor carrier on which a decorative pattern is applied and amount of resin is provided, more particularly soaked in resin, and / or impregnated with resin.

According to the invention, such "laminate product" can thus relate to the aforementioned laminate layer per se, whether or not cured, as well as any other product comprising such laminate layer. The latter other products essentially mean products that essentially consist of a substrate that is coated with such a laminate layer, whether or not combined with other layers.

An important field of application herein is laminate panels, in the first place laminate floor panels, but in the second place also laminate panels for other purposes, such as for furniture, partitions and the like. Of course, it may also concern products other than panels, such as, for example, profiles, skirting boards and the like, which contain a coating from such a laminate layer. Furthermore, such products may per se also consist of a composite layer structure in which such a laminate layer is incorporated, such as a so-called HPL (high pressure laminate) or a compact laminate of which the laminate layer realized according to the invention then forms a part thereof.

It is known to realize a laminate product which comprises at least one laminate layer, by forming a decorative sheet at least on the one hand to form a decor in the form of a design on a decor support and, on the other hand, to form a laminate layer providing the decor sheet with resin by means of a resin application process.

The decor sheet is traditionally produced by printing on a paper web with a decor. This printing is carried out at a printer, where this is traditionally achieved by means of rotary printing. The printed decor determines the appearance of the decorative side of the final product. For example, for use in floor panels, the decor usually represents an imitation of wood or stone, which in the latter case includes both natural stone and other types of stone, such as ceramics, concrete or the like, by stone. In the case of an imitation of stone tiles, cement joints or the like can also be imitated in the decor.

The decorative sheet is provided with a quantity of resin by impregnating it with resin, either by immersion in liquid resin, or by applying resin or by a combination, after which the resin is dried. Traditionally this is a step that is carried out at the manufacturer of the actual laminate product, for example at the manufacturer of the laminate floor panels, in which the decorative sheet, more specifically the printed paper web, is provided with a continuous process with resin and the drying takes place through this paper web through it one or more drying ovens.

Furthermore, various techniques are known for attaching such a laminate layer to a substrate. According to the commonly used technique of so-called direct pressure laminate (DPL), the resin-impregnated decorative sheet, or at least a part thereof, is applied to the substrate, possibly together with other layers, and the whole is consolidated by compressing it under an elevated temperature which is usually carried out in a heated press. Other layers that can be compressed simultaneously here are, for example, a so-called overlay and / or a bottom layer. The overlay is generally formed from a resin-coated paper layer in which wear-resistant particles are received, such as corundum or the like, and is applied over the decor to increase the wear resistance of the finally obtained floor panels. The paper layer of the overlay is of such a nature that it becomes almost completely transparent after pressing and consolidating. According to a variant, it is also possible to work without overlay and to use wear-resistant particles present in the resin present on the decorative sheet. The aforementioned optional bottom layer is a uniformly colored paper layer or the like that can be provided between the substrate and the decorative sheet, and which, for example, prevents color differences in the surface of the substrate from shining through into the decorative side.

When compressing the whole, it is customary that a balancing counter layer is also applied to the underside of the substrate.

According to another known technique, namely the technique of so-called high pressure laminate (HPL), the printed and resin-coated decorative sheet is first consolidated with yet other material sheets, preferably also impregnated paper webs or sheets, such that a per se relatively stable multi-layered laminate is obtained, which in turn can be attached to a substrate, for example by means of an adhesive.

According to yet another known technique, the printed and resin-coated decorative sheet is pressed with a plurality of other impregnated material layers, such that a self-supporting laminate structure is obtained, usually in the form of a thin plate, the product then obtained being called "compact laminate" , which is then generally used without a substrate.

In the case of floor, furniture or wall panels, for the aforementioned substrate, use is usually made of wood-based plate material, usually MDF (Medium Density Fiber board) or HDF (High Density Fiber board), but other materials can also be used.

A drawback with the known methods for forming a laminate product is that little interaction is possible between, on the one hand, printing of the decor sheet and, on the other hand, resins of the decor sheet, in other words between the decor application process and the resin application process, in the in particular because the printing takes place at a printer who supplies the unhardened decorative sheet to the producers of the laminate, the latter then proceeding to the resin. This has, inter alia, the consequence that a relatively large buffer stock must be stored on the printed decorative sheet, more particularly on rolls of decorative paper, at the laminate producer, since the latter must be certain to always have all the motifs available. Another disadvantage is that if a decor with a certain motif was unexpectedly no longer available, it would take quite some time before this could be supplied by the printer. A further disadvantage is that in the case of a laminate producer, two stocks of decor sheet, more particularly decor paper, often have to be created, namely unhardened decor sheet and waxed decor sheet.

Furthermore, it is known that when pressing the non-resin-impregnated decorative sheet, to cure the resin, which usually takes place when consolidating this decorative sheet with the substrate or with other material sheets, a relief can be formed in the surface, more particularly in the form of impressions. Such impressions can be made in accordance with the printed decor, which is called "registered embossed" in English. In the case of an imitation of wood, the impressions can, for example, imitate a natural relief of wood, in the form of impressions representing the pores and the like, in accordance with the printed wood pattern. It is also possible to imitate joints between different planks represented by the decor and removed wood sections by means of the indentations. In the case of a stone imitation, the natural relief of a type of stone can also be imitated in accordance with the printed decor and / or impressions can be formed to represent lower cement joints and the like.

The indentations are normally formed by using a embossed press plate.

A difficulty in forming laminate with a relief that is intended to conform to the decor is to be able to realize such correspondence in reality and this with no or slight deviations over the entire surface of the decor sheet. After all, the resin is applied to the decor sheet in the liquid state, whereby the wet decor sheet becomes susceptible to elongation and is therefore stretched during the resin application process.

It is known to take into account a certain expected stretch and therefore to print the design in a slightly smaller predetermined format than is ultimately desired, all this in such a way that the stretched design, which is obtained after waxing and drying, than dimensions shows that more or less correspond to the desired dimensions. However, due to the fact that the elongation is dependent on a large number of parameters, a number of which may moreover change during the processing of one and the same decor carrier, it is often not sufficient to only charge a predetermined elongation and the relief pattern is often not included. in accordance with the printed motif. The decorative side of the obtained laminate products can therefore display a distorted image.

A solution that can be used in certain applications consists in designing two or three pressing plates which have a uniform relief pattern, but the patterns of which each have a slightly more elongated format, such that, depending on the production batch of decor carriers, associated rack, the best matching press plate can be used. However, this technique is extremely expensive and offers only a limited solution. After all, the technique does not allow for changes that may occur in a decor carrier itself, since once a choice of pressing plate has been made, the entire decor carrier or batch of decor carriers with the chosen pressing plate is processed. Furthermore, the chosen embossing pattern will generally not fully correspond to the printed motif.

Furthermore, it is well known that a slight control of the elongation is possible in the longitudinal direction of the decor carrier by changing the tensile force with which the decor carrier is passed through the resin application process. However, this arrangement is limited and does not provide a solution for distortions in the width direction.

According to a first aspect, the present invention contemplates a method for manufacturing laminate products, wherein one or more of the aforementioned disadvantages are excluded or minimized. In general, it aims at a method that allows a generally smoother course of the production process.

More specifically, in accordance with certain preferred embodiments, the invention also contemplates a method that allows an interaction between the decor application process, i.e. printing, and the resin application process, and more particularly a technique with which the deformation in a decor due to stretch on can be done in a controlled manner.

To this end, according to a first aspect, it relates to a method for manufacturing a laminate product which comprises at least one laminate layer, wherein, to form the laminate layer, on the one hand, at least one decor sheet is formed by a decor in the form of a motif on a decor application process. to provide a decor support and, on the other hand, subsequently to provide the decor sheet with a resin application process, characterized in that said decor application process and said resin application process are performed in-line with each other.

By uin-line is meant that the decor application process and the resin application process are carried out simultaneously on a decor carrier that originates from the same production batch of decor carrier material, this in the same production line. A production line is herein understood to be an arrangement in which a decor carrier is printed with a decor and the resulting decor sheet, whether or not already divided into individual sheets, is subsequently systematically provided with resin. In other words, there is no intermediate storage of decor sheet, from which decor sheet with a desired motif can be chosen at will, but after the application of the decor the decor carrier is supplied to the resin application process via a continuous product stream. The continuous product flow does not exclude the formation of a buffer stock in between. The decor application process and the resin application process do not necessarily have to be carried out in the same production line or production hall, although this is preferred.

More specifically, it is preferred that in the production direction a length of decor sheet, either in the form of a continuous web or in the form of loose sheets, whether or not stacked, is present between the decor application process and the start of the actual resin application process which is less than 100 meters, and better still less than 20 meters.

The term decor sheet should be interpreted broadly, such that it should be understood to mean both a continuously printed web and individual sheets that have been cut to a certain length and treated one after the other.

It is clear that according to the invention, according to the above-mentioned first aspect thereof, the advantage is obtained of a smooth production method.

More specifically, in this way you can quickly switch from one design to another. The need for large stocks of decorative sheet with all kinds of motives is also excluded.

Interaction is also possible due to the in-line arrangement.

According to an important preferred embodiment of the invention, which is applicable to methods in which, as mentioned above, a deformation occurs in the decor carrier as a result of the resin application process, more particularly stretching occurs in the decor carrier, the method further has the feature that the decor application process is performed on a controlled is effected in such a way that the decor is applied to the above-mentioned decor carrier as a function of the aforementioned distortion. Such control has the advantage that, at the time of its application, the decor can be changed in size, shape and location in such a way that a compensation effect for an undesired distortion is created, as it were. In other words, this means that when printing a design, a certain deformation that is observed is taken into account and that the design is then printed with a shape and dimensions such that after deformation a desired design, so with desired shape and dimensions, is printed. left over.

Preferably, when applying the decor, a certain continuity in the size and / or location of this decor, in the form as obtained after completing the resin application process, is pursued. More specifically, for the dimensions and / or location of the decor, or for design parts thereof, as obtained after waxing, a predetermined value of the dimension or predetermined locations is aimed for.

The method in which a final decor of a certain size is sought is particularly important in the case of laminate products which are provided with a pre-set relief pattern on their surface which is intended to conform to the decor, which technique is known under the name "registered embossed". During the decor application process, the decor can then be applied in function of the deformation that such decor obtained after deformation is adapted to the aforementioned relief pattern, and is preferably in accordance with or substantially in accordance with the relief pattern.

In the most preferred embodiment, use is made according to the invention of a feedback, in which the dimensions and / or the location of the decor, or of parts thereof, in other words motif parts, are detected after waxing and in which the decor application process is functioned accordingly. controlled. Thus, corrective action can be taken with the least deviation that occurs.

It is clear that the detection can be done in any way. For example, the full width of the decor can be measured after the resin has dried, so that the elongation can be derived therefrom and, depending on the difference between the measured value and a desired value, an adjustment of the decor to be printed can be provided. According to an alternative, it is also possible to carry out a detection and check at several places across the width to also take account of any differences in elongation that occur across the width of the decorative sheet.

It is noted that the aforementioned detection can be performed at various locations in the resin application process. In the most preferred embodiment, the detection takes place after drying of the resin, because thereafter little or no distortion of the decor occurs.

However, the foregoing does not exclude the possibility that the detection may be earlier. For example, in the case that the resin is dried in two or more steps, such detection may occur between these steps. For example, if it is determined that the deformation occurs mainly prior to the second drying step, the deformation may be neglected after the detection. If, after detection, a comparatively considerable distortion still occurs, this can be taken into account, for example by means of a correction factor applied to the values obtained via the detection and / or performed by extrapolation on the detected values. In an analogous manner, it is also not impossible to carry out the detection even earlier in the resin application process, for example in the wet state for drying, after a certain elongation has already occurred.

It goes without saying that detections and measurements can also be carried out in two or more consecutive places, for example in the form of an early detection before drying, which allows a quick intervention via the feedback, and on the other hand a later detection, for example after drying , to follow up how the rack manifests itself.

Preferably, when applying the decor, at least the deformation in the width direction will be taken into account, and said feedback will then take place on the basis of detections and measurements carried out in the width direction. The width direction here is to be understood to mean the direction which is perpendicular to the direction with which the decorative sheet is guided through the resin application process.

According to another possibility, when applying the decor, at least the deformation in the longitudinal direction is taken into account. This can be achieved according to the invention by controlling the decor application process in such a way that the ultimately obtained design meets the desired dimensions. According to a variant, this can also be achieved by varying the tensile force in the decorative sheet in the wet-resined state.

In a preferred embodiment, when applying the decor, both deformation in the longitudinal direction and in the width direction will be taken into account and a suitable control is provided which ensures that the final decor, more particularly its motif, meets the desired dimensions. satisfies. It is clear that in this way any parallelogram-shaped distortion that would occur without control can also be eliminated.

It is clear that the necessary detections and measurements can be made in any way. For this, work can be done with markings which have been specially provided for this purpose in the decor and / or on its edge. It is also possible to measure the decor yourself. For this purpose optical sensors and / or cameras with image recognition can be used in a known manner.

Furthermore, it is also clear that via the feedback the dimensions of the measured stretched motif are compared with desired dimensions, and that if there is a deviation a correction in printing is realized.

In the most preferred embodiment, a printing unit will be used for applying the decor, which allows the printed design to be controlled immediately. To realize this, it is preferable that a digitally controlled printing device is used, wherein the control of the decor application process then provides for a change in the printed design. In practice, an inkjet printer or a printing device operating according to the inkjet principle can be used for this purpose. Here, both printers with a reciprocating print head can be used as so-called single-pass printers.

Implementing a change in the decor or motif can be done in various ways.

According to a first possibility, the change will consist of the relevant motif, or parts thereof, being printed on the decor carrier in a way that is stretched to a greater or lesser extent.

According to another possibility, the control of the decor application process will at least ensure that when the decor is applied, the mutual location of certain motif parts of this decor is adjusted. By this is meant that design parts of a fixed size are always pressed via the printing device, but that if the elongation is too large, these design parts are pushed towards each other, while if the elongation is too low, they are pushed apart. This can be used inter alia without any difficulty with floor panels that are realized from a larger laminate plate, wherein the design parts then, for example, each time correspond to the width of a floor panel. The fact that at the transitions between the design parts, the images would no longer fit together or overlap is no problem, since a saw cut is carried out at these places and material is milled away to form coupling means.

The resin application process is preferably carried out in a treatment street and the decor application process is also carried out in this treatment street.

Normally, the decor will be applied to the decor carrier before any waxing is performed in the in-line process. The decor carrier is then still dry and can be printed easily.

According to the invention, however, it is not excluded that a decor carrier is already provided with a certain amount of resin, after which it is, as aforementioned, provided with a decor and then again provided with resin. The advantage here is that less elongation occurs. According to the first aspect of the invention, the term "decor carrier" in that case is to be understood to mean the pre-cured decor carrier and the term "resin application process" is understood to mean exclusively the application of that resin that after the decoration has been applied is deposited on the pre-hardened decor carrier.

According to the invention, the "decor application process" is to be understood to mean a process in which at least a part of a decor, and more particularly of the motif, is applied to the decor support. When a design consists of, for example, several design parts pressed over one another, according to the invention the term "decor application process" can be understood to mean both the application of all design parts and the application of only one or a limited number of design parts.

According to the invention, it is not inconceivable that the decor carrier, before it is subjected to the decor application process referred to by the invention, is already provided with a printing, for example in the form of a foundation, a basic part of a motif, or the like.

The terms "decor sheet" and "decor carrier" are to be interpreted broadly according to the present invention and are not limited to what is traditionally understood as a decor paper. In the current application, the decorative sheet is any form of support on which a decor, more special motif or design part has been applied.

In practice, it is preferable that a rolled-up web of material is used as the starting point for the decor carrier, so that this web of material is unrolled and guided through the treatment line, and that the decor application process takes place along the web of material at a location between the web and the web. place where the first waxing takes place, or possibly on the roll itself.

The aforementioned method of the invention is particularly useful for the manufacture of laminate floor panels, wherein the decorative sheet is applied directly or indirectly to a substrate, such as an MDF or HDF board, whereafter from the substrate with the decorative layer applied thereon and any other layers, the actual laminate floor panels are formed. As usual, this is based on large plates which, after pressing the laminate on, are divided into panels and provided with coupling parts at the edges, for example as known from WO 97/47834.

It is clear that the invention also relates to laminate products manufactured according to the method of the invention, in particular laminate floor panels.

The invention also relates to a device for realizing the above-described method, characterized in that it comprises at least one supply part for the supply of a decor support and an in-line treatment line arranged thereon which at least consists of an applicator for applying resin to the decor carrier and a drying device in a liquid state, characterized in that a pressure device for applying the decor to the decor carrier is present between said supply portion and the applicator.

In a preferred embodiment, the device is further characterized in that said printing device is of the type that allows the decor to be adjusted in width, in its entirety and / or by changing the location of parts thereof; that the device is provided with a measuring device that checks at least certain deformations in the decor, and that it contains feedback with which the printing device is controlled as a function of values originating from the measuring device.

A further object of the invention is to provide a number of methods for manufacturing laminate products, wherein a number of advantageous techniques are employed in the decor application process, which methods are described below as the second to fifth aspect of the invention.

According to the second independent aspect, the invention relates to a method for manufacturing a laminate product, which comprises at least one laminate layer with a decor sheet, wherein, to form the laminate layer, at least one decor sheet is formed by a decor in the form in a decor application process of applying a design to a decor carrier, said decor carrier consisting of a continuous web of material, characterized in that the decor is applied by means of one or more digital printers and that the global decor is varied during the processing of the web of material, via control of the one or more printers, this in function of varying data. This method is intended primarily for use in mass production printing, by which is meant that a large length of said decor carrier is printed, more particularly at least 100 meters, and preferably a full roll of such decor carrier, and not a limited amount for special purposes, such as testing a new decor. By making use of digital printers in a production printing process, more particularly in mass production printing, a change and / or correction can be implemented quickly in the middle of processing the same material web. It is also advantageous that control based on external data is possible.

According to a first application possibility of the second aspect, the control takes place in function of the amount of desired decor of a certain motif. This means that in the middle of the processing of one and the same web of materials, a switch is made from the production of one particular design to another. This makes it possible to realize smaller runs of a certain motif, in contrast to traditional printing systems where printing rolls are used that are normally only exchanged after processing a complete web of material.

According to another application possibility of the second aspect, the control takes place as a function of incoming technical data from the printed decoration carrier, for example as a function of the elongation upon impregnation, derived from, for example, data from the hardening of a previously produced decoration carrier originating from the same production batch. , for example, decor paper produced from the same paper mass. The change or correction here may then, for example, consist of the motif being printed in a more or less stretched manner, to compensate for the aforementioned elongation.

According to the third independent aspect, the invention relates to a method for manufacturing a laminate product, which comprises at least one laminate layer with a decor sheet, wherein, to form the laminate layer, at least one decor sheet is formed by a decor in the form of a to apply a motif to a decor carrier, characterized in that the decor carrier is based on a prefixed paper or paper-based material. This method offers the advantage that the decor carrier is less susceptible to elongation upon wetting by the resin and therefore the decor applied to the prefixed paper or to the paper-based material essentially retains its correct dimensions. According to the invention, a practical form of pre-fixation consists in that the decor carrier, so before printing, is already partially waxed, for example with a small amount of resin, and / or is only waxed on one side, while the printing is then, for example, on the on the other side. The partial coat and of course also drying ensure that any stretch occurs before the printing and that the decor carrier comes to a stable state when dried.

It is clear that the above-mentioned methods according to the second and third aspect also come into their own especially when they are used in the manufacture of laminate products which are provided with impressions in accordance with the decor, more particularly laminate products which have a so-called "registered" embossed surface, where it is desirable that the design has precise final dimensions.

According to the fourth independent aspect, the invention relates to a method for manufacturing a laminate product, which comprises at least one laminate layer with a decor sheet, the decor sheet being formed by applying a decor in the form of a design to a decor support in a decor application process, and wherein the decor carrier is advanced at a certain nominal transit speed, characterized in that the decor carrier is thereby moved during the effective application of the decor at a local transit speed that is lower than the aforementioned nominal transit speed, that in the effective application of the decor an excess of surface is provided with a decor, and that the decor is applied intermittently, and between these intervals, local transit at an increased speed greater than the nominal transit speed takes place. The nominal throughput speed is the speed at which the decor carrier is supplied and discharged to the process. By the fact that an "excess surface is provided with a decor" it is meant that during the actual application of the decor a larger surface per unit of time is printed than the area that is moved per unit of time at the aforementioned local transit speed past the same place.

This method offers the advantage that for applying the decor, one or more printing devices can be used which per se have a printing speed that is slower than the nominal throughput speed, or in other words that the throughput speed no longer needs to be limited to the aforementioned printing speed. This offers, among other things, the possibility of working with digital printers, the printing speed of which is relatively low, while a higher nominal transfer speed can nevertheless be used.

According to a preferred embodiment of the fourth aspect, the decor carrier is supplied and discharged at a permanent or substantially permanent speed and the differences in speed are compensated by means of a buffering action. More particularly, it is preferable that the decor carrier consists of a continuous web of material and that the buffering action takes place by guiding the web of material before and after the decor application process along buffer systems with which the path to be covered by the web of material is systematically increased and reduced. Such a buffer effect offers a practical solution to compensate for speed differences.

According to the fifth independent aspect, the invention relates to a method for manufacturing a laminate product, which comprises at least one laminate layer with a decorative sheet, wherein the decorative sheet is formed by applying a decorative pattern decor to a decor support in a decorative application process, characterized in that in the decor application process use is made of several simultaneously operating digital printing devices which, in the production direction, realize their own decor parts, or thus decor segments, on mutually different surface parts of the decor carrier. Each digital printing device therefore takes on a specific surface area during printing. This method has the advantage that relatively large areas can be printed by means of digital printing devices in a relatively short time, even when they per se have a limited operating speed.

According to the present invention, the characteristics of two, three, four or even all five of the aforementioned independent aspects can be combined with one another, whereby it is clear that new advantages are thereby obtained. For example, the combination of the features of the first and fourth aspect has the advantage that, on the one hand, use can be made of digital printers for the printer, whereby the printed decor can easily be changed by electronic control, while, on the other hand, notwithstanding such printers relatively slow work, but it is possible to work with a higher transfer speed in the resin application process.

With the insight to better demonstrate the features according to the invention, a few preferred embodiments are described below as an example without any limiting character, with reference to the accompanying figures, in which: figure 1 represents a laminate layer in section and on an enlarging scale; figure 2 shows a highly schematic view and in top view an arrangement that applies a method of the invention; figure 3 represents a view according to arrow F3 in figure 2; Fig. 4 shows a plan view of a further arrangement applying a method according to the invention, together with a corresponding part of a press plate, which is also shown schematically next to it; figure 5 represents a side view of the arrangement from figure 4 in a more detailed view; Figures 6, 7 and 8 illustrate how impressions can be achieved in a laminate surface; Figures 9, 10 and 11 show how the dimensions of a decor can be adjusted; figure 12 represents a view similar to that of figure 4, but for a variant; Figures 13, 14 and 15 relate to a printed wood pattern with pressed pores; figures 16, 17 and 18 schematically represent the printing of a decor carrier, in accordance with inter alia the fourth and fifth aspect of the invention.

To clarify the method to which the invention is intended, a laminate layer 1 is shown in figure 1 which can be realized according to the invention. The laminate layer 1 here consists of a decorative sheet 2 which is provided with resin 3, wherein the decorative sheet 2 in turn consists of at least one decor support 4 and a decorative design 5 supported by it.

Traditionally, the decor support 4 here consists of a paper layer, while the decor 5 is formed by a print which has been applied to the paper layer. It is clear, however, that such decor carrier 4 and decor 5 can be constructed in any way and from any suitable material. The applied motif can be of any shape. In an important field of application of the invention, namely the production of laminate floor panels, a motif will normally be used that represents wood or stone, such that a parquet floor, wooden floor or tiled floor is imitated by means of the installed floor panels.

The resin 3 can be applied in one go or in different steps. Figure 1 shows diagrammatically a complete impregnation with resin 3, but it is clear that variants are possible, for example in which resin is assigned on only one side.

As shown in the diagrammatic representation of figures 2 and 3, the present invention relates to a method for manufacturing a laminate product, which comprises at least one laminate layer 1, wherein, to form the laminate layer 1, on the one hand, at least one decorative sheet 2 is formed by applying a decor 5 in the form of a motif to a decor carrier 4 in a decor application process 6 and, on the other hand, subsequently providing the decor sheet 2 with resin 3 by means of a resin application process 7.

The special feature of the invention is that said decor application process 6 and said resin application process are performed in-line with each other.

In the example, the decor carrier 4 consists of a flexible material web, such as a paper web, which is supplied from a supply 8, in this case a roll 9 from which the decor carrier 4 is unwound in the form of a material web. It is clear that the supply 8 is included in a suitable frame or the like, which can then be designated as supply part.

The application of a decor 5 in the decor application process 6 is effected by means of a printing device 10.

To realize the resin application process 7, a device 11 is used which comprises at least one applicator 12 for applying the resin 3 to the decorative sheet 2 in the wet state, as well as a drying device 13 for drying the resin 3.

It is clear that furthermore the necessary transport means are provided for guiding the decor carrier 4 through the total device 14, which, however, are not shown in the schematic representation of figures 2 and 3.

In figure 3, the applicator 12 is only schematically represented as an impregnation device, wherein the decorative layer 2 is guided through the resin 3. However, it is clear that in practice any suitable device can be used for this purpose. Some examples of techniques for applying resin to a decorative sheet are impregnation by immersion, application by means of one or more rollers, spraying of resin, spraying of resin via a spray nozzle, and so on. Various of these techniques can be combined with each other.

The drying device 13 can of course also be of any construction. In practice, it usually consists of two drying tunnels arranged one behind the other.

In essence, the arrangement of figures 2 and 3 means that the resin application process is carried out in a treatment line, which can be of a traditional construction per se, while the special feature is that the decor application process 6 is also realized in this treatment line.

It is clear that by performing the aforementioned processes in-line, the advantages described in the introduction are obtained.

It is known from practice that the contact carrier 4 will generally wake up due to the contact with the wet resin 3 and will stretch during transport through the device 14, both in length and width. This then leads to a state in which the decorative sheet 2 and therefore also the motif applied to it stretch out, which is shown in an exaggerated extent in Figure 4, wherein the printed decorative sheet 2 has an initial width IW and, after being coated, obtains an end width EW that is larger. In reality, this is a stretch of usually only a few millimeters, for example 2 millimeters, over a width of, for example, 2 meters.

As explained in the introduction, there are various applications where such an elongation, even if it is only 2 millimeters, is undesirable, or at least where it is desired that the elongation is admitted, but is under control such that ultimately a motif is obtained that meets specific dimensions. This is the case, for example, in the production of laminate products which are provided with an embossed relief on their surface which is intended to conform to the printed design, and therefore the final design, i.e. after drying of the resin, must meet very precise dimensions.

The need for such accuracy is explained in more detail below with reference to the example shown in Figures 4 to 8, where the produced motif is a tile motif for laminate floor panels, with printed joints 16 between the printed tile surfaces 15, for example for imitating cement joints are present, and the intention is to compress the obtained laminate layer 1 onto a substrate 17, such that the surface 18 of the compressed laminate product 19 is pressed in at the joints, so as to provide deeper joints with these indentations 20 imitate.

Figure 5 shows the process of Figure 4 in side view, together with a number of other steps. Analogously to FIGS. 2 and 3, a decor carrier 4, more particularly paper, is unwound from a roll 9 and passed through the device 14 and thereby provided with a decor 5 and with resin 3. At the end of the waxing process, at least in the example shown, the resin-coated decorative sheet, here referred to as laminate layer 1, is divided into individual sheets 21 which can then be pressed onto a substrate 17 in a later step. in Figure 5, such individual sheet 21 is then each time compressed together with a substrate 17 in a press 22 to be consolidated under heat and pressure. In this case, other layers of material may or may not be compressed, such as, for example, a counter-layer 23, which exerts a balancing effect, such as a so-called overlay 24 which may contain wear-resistant particles, which layers in this case also consist of resin-impregnated paper layers 25- 26 exist.

Pressing of the decorative side takes place with the intervention of a pressing element which is provided with a relief which creates the desired impressions on the surface of the laminate product to be realized. In the example shown this pressing element consists of a pressing plate 27, but it is clear that any other pressing element can be used to form the indentations, which should also be understood to include a so-called release foil. The successive figures 6, 7 and 8 illustrate the use of such a pressing plate for the aforementioned tile motif. Figure 6 shows the press plate 17 in cross section, while Figure 7 shows a corresponding part of the decor and Figure 8 shows the pressed laminate product 19 in a corresponding way, which may then have to be further sawn into floor panels. Protected sections 28 are provided on the pressing element in accordance with the joints 16 shown in the decor, the width of which corresponds to the joints, so that after pressing, impressions 20 are formed at the places where the printed joints 16 are located.

It is clear that the relief 29 on the pressing plate 27 has fixed dimensions. On the other hand, the motif of the decor can change depending on the aforementioned occurring stretch, the value of which is never known with certainty beforehand, which can thus result in the elongated motif no longer being in accordance with the pattern of the relief 29 of the press plate 27.

According to the invention this is remedied by allowing the decor application process 6 to run in a controlled manner and thereby applying the decor 5 to said decor carrier 4 as a function of the relevant deformation, while, like the aforementioned, the decor application process 6 is in-line with the resin application process 7 is carried out. This technique allows the decor 5 to be adjusted initially, so during the application, in function of the elongation, with the result that the end result also changes. In this way a certain continuity in the size and / or location of the decor, in the form as obtained after going through the resin application process 7, can be pursued. More specifically, for the dimensions and / or the location of the decor, or parts thereof, as obtained after waxing, a predetermined value of the dimension or predetermined location is aimed for.

Such an adjustment of the decor preferably takes place at least in the direction of the width of the material web, although an adjustment in the length, or also in both directions, is not excluded.

As shown in figures 4 and 5, feedback is preferably used 30, wherein the dimensions and / or the location of the decor are detected after waxing with the aid of a measuring device 31 and wherein the decor application process 6, or therefore the printing device 10, is controlled based on this.

In the example shown, the deformation in the width direction is taken into account, and the effective decor width is measured by means of the measuring device 31, either on the basis of the overall width or on the basis of certain parts of the web of material.

The adjustment of the decor as a function of the values observed by the measuring device 31 can take place in various ways.

Figures 9 and 10 illustrate a first possibility in which the adjustment is made by applying the relevant motif, or parts thereof, to the decor in a way that is stretched to a greater or lesser extent. These figures represent on the left a portion from the aforementioned tile motif prior to the dressing, while on the right the same portion is shown after dressing.

Figure 9 shows a state where the initial dimension measured between the centers of the joints 16 is a value DB1. After applying the wet resin and drying it, this results in a final dimension DE1 which in this case is smaller than a desired predetermined final dimension DW with which DE2 should correspond. According to the invention, it is now observed via measuring device 31 how great the deviation between the size of the obtained decor and the size of the desired decor are. Via the feedback the decor is then printed to a larger rescaled value, with an initial dimension DB2 that is larger than DB1, such that, as shown in Fig. 10, the resulting final dimension DE2 corresponds to or substantially corresponds to the desired final dimension DW. It is clear that an adjustment of the decor can thus always be provided. The changes in one material web, in other words, the support, are generally gradual, and the aforementioned feedback can therefore be used sufficiently quickly to limit differences between the size of the decor obtained and the desired size thereof.

As aforesaid, a printing device is preferably used for applying the decor, which allows the printed motif to be controlled immediately. Preferably, therefore, use will be made of one or more digital printers and more specifically of one or more printers that work according to the inkjet principle. The use of a digital printer makes it possible to instantly resize the printed design over the entire surface, which is impossible, for example, with a printing unit with pressure rollers.

Fig. 11 illustrates another possibility of adapting the decor as a function of the elongation, the actual decor not being subjected to a uniform, continuous continuous resizing, but the decor being subdivided into design parts that are shifted more or less apart, in other words, the mutual location of certain design parts of this decor is adjusted.

Figure 11 is conceived to represent a solution to the undesirable condition of Figure 9. With this possibility, a printed design part has a fixed dimension, which is equal to DB1, this design part comprising a printed tile surface 15, as well as a part at the edges of the printed joints 16. Fig. 9 shows, as aforesaid, an initial state, wherein the respective motif part assumes, due to the occurring strain, an end dimension DE1 that is smaller than the proposed end dimension DW. It is pointed out here that the design part obtained is not only too small, but is also no longer centered relative to the location where the elongated design part should be located, namely the area where DW is shown in the figure. According to the solution of Fig. 11, an adjustment is realized by printing the design part with the same size, that is to say with an initial dimension DB1, but shifting this design part over a distance S, which is chosen such that the design part obtained after stretching, which then has the same final size DE1, as in Figure 1, will be centered in the zone indicated by DW. It is clear that in this way differences between a printed design and a possible relief pattern of a press plate 27 can be reduced to a minimum.

The mutual location of the design parts can be changed in various ways. When, for example, a digital printer is used that extends across a plurality of design parts in the width and, for example, over the full width of the decorative sheet, it can be controlled such that the design parts, depending on the measured elongation, extend a greater or lesser distance from each other. be printed together.

The subdivision into design parts also makes it possible to work with individual printing units, wherein, in order to realize the aforementioned control, these printing units are displaced relative to each other. Figure 12 shows an example of this, in which the mutually displaceable printing units are schematically indicated with reference 32. Together they form a printing device 10.

According to a first possibility, the printing units 32 are controlled in such a way that they are always centered with respect to the place where they are to realize the decor, and each design part per se is printed over an appropriate width dimension.

According to a second possibility, printing units 32 with fixed printing widths are used and only a suitable centering is provided via the control. This technique has the advantage that it is possible to work with printing units of which the printing width is not per se changeable, so for example also with pressure rollers.

It is clear that when different colors are used, multiple parts of printing units can be placed one after the other, all of which are then controlled synchronously.

Although the invention has been described above with reference to a tile motif, it is clear that it does not only come into its own with such motifs, but is applicable to all laminate applications in which an uncontrolled stretch leads to deviations from the desired result.

Figures 13 to 15 illustrate yet another application of a laminate product with a wood pattern.

Figure 13 shows the finished decorative side with a printed image with zones A that are of a different shade of color than the zones B, whereby in the zones A impressions are formed which imitate the pores of the wood. Fig. 14 only shows the decor, while Fig. 15 shows the motif of the indentations 20 per se, which is therefore also a representation of the embossed pattern 33 used. From this it is clear that if the decor would no longer conform to the pattern after being waxed motive, the effect of Figure 13 is never obtained. More specifically, it is known that dim unwanted effects would occur.

Finally, a special technique is shown in figures 16 to 18 for printing on a decorative sheet 4, which can be used advantageously in the realization of the method according to the first aspect of the invention, but which also forms an example of, inter alia, the fourth and fifth independent aspect of the invention.

The decor carrier 4 is thereby advanced with a certain nominal throughput speed V1. This means that the supply as well as discharge of the decor carrier 4 takes place at the aforementioned speed V1. However, it is special here that the throughput speed V2 with which the decor support 4 is advanced during the effective application of the decor 5 is lower than the aforementioned nominal throughput speed V1; that upon the effective application of the decor 5 an excess surface is provided with a decor, in other words a larger surface is provided with decor 5 than if the decor 5 were applied at the speed V2; and that the decor 5 is applied intermittently, and between these intervals, a feed-through takes place at an increased speed V3.

In order to realize this, in the example shown, several printing devices arranged one behind the other, in this case three, respectively 10A, 10B and 10C, are used, each of which realizes its own decor parts or decor segments 34A, 34B and 34C. Before and after this group of printing devices there are buffer systems 35 and 36 that allow to compensate for and / or cause the differences between the speeds V1, V2 and V3, which in the example shown consist of movable rollers 37-38 and 39-40 , which form systems with which the path to be traveled through the material web can be systematically enlarged and reduced.

The operation can be easily derived from the successive operation states shown in Figures 16, 17 and 18.

In the state of Figure 16, the decor carrier 4 is supplied at a speed V1. The rollers 37 and 38 are displaced from each other with the result that the decor carrier 4 leaves the buffer system 35 at a smaller speed V2. The printing devices 10A, 10B and 10C then arrange the respective decor segments 34A, 34B and 34C one after the other on the decor carrier. In order to obtain that the decor carrier can be discharged at the slit V1, more material is taken from the buffer system 36 than is fed in, for which purpose the rollers 39 and 40 are moved towards each other.

Figure 17 shows the state when the decor segments 34A, 34B and 34C are practically fully realized.

After the decor segments 34A, 34B and 34C have been fully realized, the printed portion is rapidly shifted at increased speed V3, wherein to store the speeds V1 at the input and output, the buffer systems 35 and 36 are appropriately controlled by the rollers 37- 38 together and moving the rollers 39-40 apart.

It is clear that the mutual displacement between the rollers 37 and 38, as well as between the rollers 39 and 40, will take place via suitable drive and / or transmission means in order to, depending on the intended cycle, extend or shorten the path to be followed. whose construction is within the reach of those skilled in the art. It is also clear that bending bars can be used instead of rollers. Other buffer systems are also possible.

From the embodiment of the invention described above with reference to Figures 16 to 18, it is clear that the local transit speed V2 at the level of the pressure devices 10A, 10B and 10C will be significantly lower than the general transit speed V1, which offers the advantage that it is now also possible to work with printing devices which in themselves print relatively slowly, while still allowing a higher general throughput. This offers a practical solution for using digital printers, such as digital inkjet systems, the speed of which is generally relatively limited, without the general throughput speed having to be limited to the operating speed of such a digital printer. It is clear that such a system is therefore advantageous for use in the first aspect of the invention, in which case, for example, the printing device 10 from figures 2 to 5 is replaced by an arrangement such as in figures 16 to 18, for example with digital printers. The digital printers then allow easy control by the feedback, while the multi-printer arrangement 10A, 10B and 10C allows the printed decor sheet to be fed at a speed V1 through the treatment device that is larger than V2. In this way, the speeds V2 and V1 can each be optimized as a function of the relevant operation, in this case respectively the printing and the resin.

The present invention is by no means limited to the embodiments described as examples and shown in the figures, but such a method for manufacturing floor panels, as well as the floor panels obtained thereby and devices used for this purpose can be realized according to different variants without departing from the scope of the present invention. to enter.

Claims (22)

A method for manufacturing a laminate product comprising at least one laminate layer (1), wherein, to form the laminate layer (1), on the one hand, at least one decor sheet (2) is formed by a decor (6) in a decor application process (6) 5) to be applied to a decor support (4) in the form of a motif and, on the other hand, subsequently to provide the decor sheet (2) with a resin application process (7) with resin (3), characterized in that said decor application process (6) ) and said resin application process (7) are carried out in-line with each other. Method according to claim 1, wherein a deformation occurs in the decor carrier (4) as a result of the resin application process (7), more particularly stretching occurs in the decor carrier (4), characterized in that the decor application process (6) takes place in a controlled manner and in that case the decor (5) is applied to said decor carrier (4) as a function of said deformation. Method according to claim 2, characterized in that when applying the decor (5) a certain continuity in the size and / or location of this decor (5), in the form as obtained after completing the resin application process (7) , is pursued. Method according to claim 3, characterized in that for the dimensions and / or location of the decor (5), or of parts of which are obtained after resin, a predetermined value of the size or predetermined location is sought. Method according to one of claims 2 to 4, characterized in that the laminate product (19) is provided on its surface with a predetermined relief pattern which is intended to be in accordance with the decor (5); and that the decor (5) is arranged during the decor application process (6) in function of the occurring deformation such that the decor (5) as obtained after deformation is adapted to the aforementioned relief pattern, and preferably in accordance with or substantially in accordance with is the relief pattern. Method according to one of claims 2 to 5, characterized in that use is made of a feedback (30), wherein the dimensions and / or the location of the decor (5) after waxing and preferably after drying of the resin ( 3) are detected and the decor application process (6) is controlled as a function thereof. Method according to one of Claims 2 to 6, characterized in that the decor carrier (4) has a width and a length direction and that at least the deformation in the width direction is taken into account when applying the decor (5). Method according to one of Claims 2 to 7, characterized in that the decor carrier (4) has a width and a length direction and that at least the deformation in the length direction is taken into account when applying the decor (5). ü Werkwiye 6: '',> ··· .: ύί; • '.r.n.ciai-ics 2 ίο ί. } · ./ .. · (ιοπο: .. οο <;, ·· οίο · ..: ·· The method according to one of claims 2 to 8, characterized in that for the: 00; o ·.: · "· · ;, ·:« u · u go oho: - o: o :: · applying, tie ^ t .. (feqpr. $ £). the printed decor (5), and a spitgale. The print is jerked, instantaneously controlled, more specifically a digitally controlled printing unit, and that the control of the decor application process (6) provides for a change in the printed motive. Method according to claim 9, characterized in that the change consists in that the relevant motif, or parts thereof, on an in. more or less stretched way is printed on the decor carrier (4). The method according to any of claims 2 to 10. characterized by that by controlling the cycle decorating process. (6). at least it is achieved that when applying the decor (5) the mutual location of certain design parts of this decor (5) is adjusted. Method according to one of the preceding claims, characterized in that the resin application process (7) is completed in a treatment street and that the decor application process (6) also takes place in the treatment street. Method according to claim 12, characterized in that the decor (5) is applied to the carrier before any resin is carried out in the in-line process. Method according to claim 12 or 13, characterized in that for the decor carrier (4) a rolled-up material web is assumed, which thus forms a roll (9), wherein this material web is unrolled and guided through the treatment street, and that the decor application process (6) takes place along the material web at a location between the roll (9) and the place where the first waxing takes place, or possibly on the roll (9) itself. Method according to one of the preceding claims, characterized in that the decor (5) is applied to the decor carrier (4) by means of at least one digital printing device (10; 10A-10B-10C) or digital printing unit (32), more especially a digital printer, and in the case of an inlcjet printe.r. ^^ ^^. ............ hei in · ^ ne process egg> egg; jeeni :; wcrot. A method according to any one of the preceding claims, characterized in that it is used for the manufacture of laminate floor panels, wherein the decorative sheet (2, 21) is applied directly to a substrate (17), after which From the substrate (17), which then at least contains the decprvël (2), the actual laminate floor panels are embossed. ., ".... 17," Butterfly panel, characterized in that it is obtained according to the method of claim 16. ... jiHSv'M- ·: o; . h. ssu. Device for carrying out the method according to one of claims 1 to 16. characterized in that it comprises at least one supply part for the supply of a decor support (4) and one. in-line. an ophthalmic treatment line comprising at least an applicator (12) for applying resin (3) to the decor carrier (4) in a liquid state and a drying device (13), characterized in that a pressure device is provided between said supply section and the applicator (12). (10; 10A-10B-10C) for applying the decor (5) to the decor support (4). Device according to claim 18, characterized in that said printing device (10) is of the type that allows the decor (5) to be adjusted in width, in its entirety and / or by changing the location of parts thereof; that the device is provided with a measuring device (31) which controls at least certain deformations in the decor (5), and that it contains a feedback (30) with which the printing device (10) is adjusted as a function of values originating from the measuring device (31) controlled. A method of manufacturing a laminate product comprising at least one laminate layer (1) with a decorative sheet (2), wherein, to form the laminate layer (1), at least one decorative sheet (2) is formed by a decorative application process (6) ) applying a decor (5) in the form of a motif to a decor carrier (4), said decor carrier (4) consisting of a continuous web of material, characterized in that the decor (5) is applied by means of one or more digital printers and that the global decor (5) is varied during the processing of the web of materials, via control of the one or more printers,% this in function of varying, e) external data ,. 21. A method of manufacturing a laminate product as claimed in claim 20, characterized in that for the decoration carrier. (4) based on a pre-fixed paper or pre-fixed paper-based material. . Method according to claim 20 or 21, characterized in that it is used in the manufacture of laminate products provided with indentations corresponding to the decor (5), more particularly laminate products which are of a so-called "registered embossed" surface are provided. Method according to one of claims 20 to 22, characterized in that the decor carrier (4) is moved at a specific nominal throughput speed (V1), characterized in that the decor carrier (4) is thereby during the effective application of the decor (5) is moved with a local transit speed (V2) lower than the aforementioned nominal transit speed (V1), that when applying the decor (5) an excess surface is provided with a decor (5), and that the application of the decor The decor (5) occurs intermittently, and between these intervals, local feeding takes place at an increased speed (V3) greater than the nominal feeding speed (V1). Method according to claim 23, characterized in that the decor carrier (4) is supplied and discharged at a permanent or substantially permanent speed and that the differences in speed are absorbed by means of a buffering action. The method according to claim 24, characterized in that the decor carrier (4) consists of a continuous web of material and that the buffering action takes place by guiding the web of material before and after the decor application process (6) along a buffer system (35-36) with which the material path is systematically enlarged and reduced Method according to one of Claims 20 to 25, characterized in that the decor application process (6) uses morphere simultaneously active design elements and which, in the production direction, have their own decorative parts located one behind the other. , or thus realize decor segments (34A, 34B, 34C) on mutually sliding surface parts of the decor carrier (4). f -